Electrically conductive carbon nanotube wire having a metallic coating and methods of forming same

Abstract

An attachment device includes a central body formed of a plastic material and defining a cavity configured to receive a temperature probe and a plurality of straps extending from the central body. Each strap of the plurality of straps is configured to secure a cable to the central body. The central body defines a wall having a first side configured to be in contact with the temperature probe and a second side in contact with a cable. This attachment device may notably be used in an electrical connection assembly having a connector, a temperature sensor disposed within the device, and at least two cables.

We claim: 
     
       1. A multi-strand electrical wire assembly comprising:
 a plurality of elongate strands consisting essentially of carbon nanotubes having a length of at least 50 millimeters; 
 a conductive coating covering an outer surface of the plurality of carbon nanotube strands having greater electrical conductivity than the plurality of carbon nanotube strands; and 
 an electrical terminal attached to an end of the assembly by an attachment means selected from the list consisting of soldering and crimping. 
 
     
     
       2. The multi-strand electrical wire assembly according to  claim 1 , wherein the conductive coating consists essentially of a metallic material selected from the list consisting of tin, nickel, copper, gold, and silver. 
     
     
       3. The multi-strand electrical wire assembly according to  claim 2 , wherein the conductive coating has a thickness of 10 microns or less. 
     
     
       4. The multi-strand electrical wire assembly according to  claim 1 , wherein the conductive coating is applied to the outer surfaces of the plurality of elongate strands by a process selected from the list consisting of electroplating, electroless plating, draw cladding, and laser cladding. 
     
     
       5. The multi-strand electrical wire assembly according to  claim 1 , further comprising an insulative jacket formed of a dielectric polymer material covering the plurality of elongate strands. 
     
     
       6. A method of manufacturing an electrical conductor, comprising the steps of:
 providing a plurality of elongate strands consisting essentially of carbon nanotubes having a length of at least 50 millimeters; and 
 covering an outer surface of the plurality of carbon nanotube strands with a conductive coating having greater electrical conductivity than the plurality of carbon nanotube strands; and 
 providing an electrical terminal, wherein the process further comprises at least one step selected from the list comprising of: 
 crimping the electrical terminal to an end of the plurality of carbon nanotube strands; and 
 soldering the electrical terminal to an end of the plurality of carbon nanotube strands. 
 
     
     
       7. The method according to  claim 6 , wherein the conductive coating consists essentially of a metallic material selected from the list consisting of tin, nickel, copper, gold, and silver. 
     
     
       8. The method according to  claim 7  wherein the conductive coating has a thickness of 10 microns or less. 
     
     
       9. The method according to  claim 8 , wherein the step of covering the outer surface of the plurality of carbon nanotube strands includes the sub-steps of placing the plurality of carbon nanotube strands in an ionic solution of the metallic material and passing an electric current through the carbon nanotube strand. 
     
     
       10. The method according to  claim 7 , wherein the step of covering the outer surface of the plurality of carbon nanotube strands includes the sub-steps of wrapping the outer surface of the plurality of carbon nanotube strands with a thin layer of the metallic material and drawing the plurality of carbon nanotube strands through a mandrel. 
     
     
       11. The method according to  claim 7 , wherein the step of covering the outer surface of the plurality of carbon nanotube strands includes the sub-steps of applying a powder of the metallic material to the outer surface of the plurality of carbon nanotube strands and applying heat to sinter the powdered metallic material. 
     
     
       12. The method according to  claim 11 , wherein the sub-step of applying heat is performed using a laser. 
     
     
       13. The method according to  claim 7 , wherein the step of covering the outer surface of the plurality of carbon nanotube strands includes using an electroless plating process to apply the metallic material to the outer surface of the carbon nanotube strand. 
     
     
       14. A multi-strand electrical wire assembly formed by a process comprising the steps of:
 providing a plurality of elongate strands consisting essentially of carbon nanotubes having a length of at least 50 millimeters; 
 covering an outer surface of each carbon nanotube strand with a metallic material having greater electrical conductivity than the strand, wherein the metallic material is selected from the list consisting of tin, nickel, copper, gold, and silver; 
 arranging the plurality of carbon nanotube strands such that one central strand is surrounded by the remaining strands in the plurality of strands; and 
 providing an electrical terminal, wherein the process further comprises at least one step selected from the list comprising of: 
 crimping the electrical terminal to an end of the plurality of carbon nanotube strands; and 
 soldering the electrical terminal to an end of the plurality of carbon nanotube strands. 
 
     
     
       15. The assembly according to  claim 14 , wherein the step of covering an outer surface of each strand is performed using a process selected from the list consisting of electroplating, electroless plating, draw cladding, and laser cladding.